Method and system for configuring programmable io controllers and searching connectable io modules thereof

ABSTRACT

The exemplified methods and systems facilitates the configuring of IO devices and its IO modules (and submodules) in enabling an operator to retrieve, via a single input, in a development workspace, a list of IO modules and submodules that is compatible to a given IO device. The exemplified methods and systems facilitates retrieval of compatible IO modules and submodules based parameters of the IO modules and submodules. The exemplified methods and systems provide an intuitive interface, in a development workspace for configuring an IO device, to add a retrieved (i.e., searched) module or submodule from a list thereof to an existing project for a given IO device.

FIELD OF THE DISCLOSURE

Embodiments of the disclosure generally relate to controls of industrialsystems, and more particularly methods and systems for managing andconfiguring controllers therein.

BACKGROUND

Industrial automation systems can include tens to hundreds ofcontrollers to monitor and control sets of subsystems. Examples of suchapplications include a power plant, a factory, a refinery, a powerdistribution site, a wind or solar farm, building systems, among others.

One type of controllers in an industrial automation system has slots toreceive mountable input-output modules and submodules to tailor the IOof the controller for a specific industrial automation application. Theindividual input-output module and submodule may include numerousdigital and analog input and/or output channels to monitor or sense avariety of different types of input signals such as thermocouple inputs,resistance temperature detectors (RTDs), currents, voltages,capacitances, inductances, and resistances, and provide correspondingoutputs. Once coupled to the controller, the controller and itsinput-output modules (and submodules thereof) are programmablyconfigurable, via a development software, with a specific hardwareconfiguration for each respective input-outputs.

As industrial communication networks grow in complexity, theconfiguration of devices in such industrial networks becomes aresource-intensive endeavor. For example, each individual controller,such as programmable logic controllers and supervisory control and dataacquisition (SCADA) systems, may have tens to hundreds of input-outputmodules and submodules. The process of configuring IO devices andmodules (i.e., to establish configuration of the IO devices and modules)is, for the most part, a manual operation. That is, in the developmentsoftware, an operator would set individual parameters for, for example,a given IO devices and its modules or submodules.

What are needed are devices, systems and methods that overcomechallenges in the present art, some of which are described above.

SUMMARY

The exemplified methods and systems facilitate the configuring of IOdevices and its IO modules (and submodules) by an operator inretrieving, via a single search input, in a development workspace, alist of IO modules and submodules that is compatible to slots of a givenIO device. The retrieved compatible IO modules and submodules may bebased on a class type (e.g., Profinet version), power consumption,dimension, operating temperature, number of port connectors, minimumupdate rate, number of IO modules per slot (or node), maximum data rate,number of supportable Daps, among others. To this end, an operator mayretrieve, intuitively, e.g., from a device- or IO-module file, acomprehensive list of compatible IO modules and submodules for a givenclass of IO device based on parameters of the IO modules and submodules.Individual IO modules presented in the resulting list may be selected,e.g., by being dragged, from a presented IO list pane, to aconfiguration pane, in the development workspace. To this end, theexemplified methods and systems provide an intuitive interface, in thedevelopment workspace for configuring an IO device.

In addition, the exemplified methods and systems facilitates, via theuser interface, a guided interface to leverage historical retrievedparameters and previously-built IO-device configuration (and itsrespective IO module configuration) as a baseline or initialconfiguration for a given IO-device configuration project. In someembodiments, the exemplified methods and systems facilitate thepresentation, via the development workspace, of similar searches ofcompatible IO modules and submodules for a given IO device.

In some embodiments, the exemplified methods and systems facilitate thepublication of popular IO device configurations and their respective IOmodules and submodules.

According to an aspect, a method is disclosed for configuring a hardwaredevice in an industrial automation system. The method includes, in adevelopment workspace for configuring hardware configuration of aplurality of input-output (IO) modules each operatively connected to aslot of an IO hardware device, presenting, by a processor, via adisplay, i) on a first pane of the development workspace, one or moregraphical elements each corresponding to an IO module slot associatedwith the IO hardware device, and ii) on the development workspace, asearch input comprising a graphical element corresponding to an inputtext field; upon receiving an input character string in the input textfield, determining, by the processor, one or more matched IO modules,from a collection of IO modules compatibly associated with the IOhardware device, having a hardware description value matching the inputcharacter string, wherein the hardware description value are associatedwith (e.g., loaded, duplicated, or indexed from) a hardware descriptionfile; presenting, by the processor, via the display, on a second pane ofthe development workspace, one or more graphical elements eachcorresponding to a given matched IO module; and upon receiving aselection (e.g., a “drag-and-drop” or a selection of correspondingcheckboxes, or the like), in the second pane, of a presented graphicalelement corresponding to a matched IO module and, in the first pane, apresented IO module slot, updating presentation of the graphical elementassociated with the selected IO module slot with a graphical elementassociated with the selected IO module.

In some embodiments, the method includes retrieving, by the processor,hardware configuration data associated with the selected IO module; andupdating, by the processor, software configuration of the developmentworkspace, wherein the software configuration is subsequently convertedto configuration instructions to be transmitted to the IO hardwaredevice to configure hardware configuration of the plurality of IOmodules connected thereto.

In some embodiments, the first and second panes proximally border eachother.

In some embodiments, the graphical element comprising the input textfield is presented in a pane selected from the group consisting of thefirst pane (e.g., presenting the IO module slot), the second pane (e.g.,the search result pane), and a third pane of the development workspace.

In some embodiments, the step of determining the one or more matched IOmodules comprises comparing the received character string to hardwaredescription of each IO modules compatibly associated with the IOhardware device.

In some embodiments, the hardware description of a given IO modulecomprises IO description data selected from the group consisting of: anumber of analog inputs, a number of analog outputs, a number of digitalinputs, and a number of digital outputs.

In some embodiments, the input character string comprises a string valuecorresponding to a slot-compatible search, the method comprising:parsing, by the processor, hardware description of each IO modulescompatibly associated with the IO hardware device; and for each TOmodule having a hardware description determined to have an operable slotrange value that includes the string value corresponding to theslot-compatible search, presenting, by the processor, on the second paneof the development workspace, a graphical element corresponding to thegiven IO module.

In some embodiments, the step of parsing hardware description of each IOmodules compatibly associated with the IO hardware device comprises:parsing each hardware description data associated with each given IOmodule.

In some embodiments, the step of parsing hardware description of all IOmodules compatibly associated with the IO hardware device comprises:determining a description type (e.g., an XML, attribute) for the inputcharacter string from a list of potential description type; and parsinghardware description data associated with a determined description typefor each given IO module.

In some embodiments, the input character string comprises a string valuecorresponding to a power-limit-compatible search, the method comprises:determining, by the processor, an available power value for the IOhardware device by subtracting a maximum available power value for theIO hardware device with a current power usage value for a currentconfiguration of the IO hardware device (e.g., wherein the current powerusage value is determined by retrieving a power requirement value foreach IO module presented in the first pane and aggregating the retrievedpower-requirement values); parsing, by the processor, hardwaredescription of power requirement value of each IO modules compatiblyassociated with the IO hardware device; and for each given IO modulehaving, in the hardware description, a power requirement value less thanthe determined available power value, presenting, by the processor, onthe development workspace (e.g., on the first, second, or third pane), agraphical element corresponding to the given IO module.

In some embodiments, method includes presenting, by the processor, viathe display, in the development workspace, graphical representation ofthe available power value for the IO hardware device.

In some embodiments, the input character string comprises a string valuecorresponding to a temperature compatible search, the method comprising:parsing, by the processor, hardware description of each IO modulescompatibly associated with the IO hardware device; and for each IOmodule having a hardware description determined to have an operabletemperature operating range value that includes the string valuecorresponding to the temperature compatible search, presenting, by theprocessor, on the second pane of the development workspace, a graphicalelement corresponding to the given IO module.

In some embodiments, the input character string comprises a stringcorresponding to a dimensions-compatible search, the method comprising:parsing, by the processor, hardware description of each IO modulescompatibly associated with the IO hardware device; and for each IOmodule having a hardware description determined to have a maximumdimension value less than the string value corresponding to thedimensions-compatible search, presenting, by the processor, on thesecond pane of the development workspace, a graphical elementcorresponding to the given IO module.

In some embodiments, the input character string comprises a stringcorresponding to a search parameter selected from the group consistingof Maximum Dimensions (e.g., length), Minimum Operating Temperature,Maximum Operating Temperature, Number of Port connectors, Minimum Updaterate support, Number of analog IO channels per module, Number of digitalIO channels per module, Number of temperature IO channels per module,Maximum TO data rate per device, and Number of Daps supported; themethod includes determining, by the processor, a hardware descriptiontype associated with the search string type; and parsing, by theprocessor, hardware description of each IO modules compatibly associatedwith the IO hardware device; and for each IO module having a hardwaredescription determined to have a value that meets the criteria of thesearch parameter, presenting, by the processor, on the second pane ofthe development workspace, a graphical element corresponding to thegiven IO module.

In some embodiments, the method includes presenting, by the processor,via the display, graphical representation of IO module configurationsfor a past-built IO hardware device, wherein the past-built IO hardwaredevice has a first slot configuration and the IO hardware device has asecond slot configuration, wherein the first slot configuration is thesame with the second slot configuration.

In some embodiments, the method includes presenting, by the processor,via the display, graphical representation of one or more historicalsearch string submitted for the given IO hardware device, wherein thehistorical search string includes a portion of the input characterstring.

In some embodiments, the method includes presenting, by the processor,via the display, graphical representation of most used IO modules forthe IO hardware device.

According to another aspect, a system is disclosed for configuring an IOhardware device in an industrial automation system via a developmentworkspace for configuring hardware configuration of a plurality of IOmodules each operatively connected to a slot of the IO hardware device.The system includes a processor; a memory having instructions storedthereon, wherein the instructions, when executed by the processor, causethe processor to: present, via a display, i) on a first pane of thedevelopment workspace, one or more graphical elements each correspondingto an IO module slot associated with the IO hardware device, and ii) onthe development workspace, a search input comprising a graphical elementcorresponding to an input text field; upon receiving a character stringin the graphical element, determine one or more matched IO modules, froma collection of IO modules compatibly associated with the IO hardwaredevice, having a hardware description value matching the input characterstring, wherein the hardware description value are associated with ahardware description file; present, via the display, on a second pane ofthe development workspace, one or more graphical elements eachcorresponding to a given matched IO module; and upon receiving aselection, in the second pane, of a presented graphical elementcorresponding to a matched IO module and, in the first pane, a presentedIO module slot, update presentation of the graphical element associatedwith the selected IO module slot with a graphical element associatedwith the selected IO module.

According to another aspect, a computer readable medium is disclosed forconfiguring an IO hardware device in an industrial automation system.The computer readable medium having instructions stored thereon, whereinthe instructions, when executed by the processor, cause the processorto: present, via a display, i) on a first pane of the developmentworkspace, one or more graphical elements each corresponding to an IOmodule slot associated with the IO hardware device, and ii) on thedevelopment workspace, a search input comprising a graphical elementcorresponding to an input text field; upon receiving a character stringin the graphical element, determine one or more matched IO modules, froma collection of IO modules compatibly associated with the IO hardwaredevice, having a hardware description value matching the input characterstring, wherein the hardware description value are associated with(e.g., loaded, duplicated, or indexed from) a hardware description file;present, via the display, on a second pane of the development workspace,one or more graphical elements each corresponding to a given matched IOmodule; and upon receiving a selection, in the second pane, of apresented graphical element corresponding to a matched IO module and, inthe first pane, a presented IO module slot, update presentation of thegraphical element associated with the selected IO module slot with agraphical element associated with the selected IO module.

According to another aspect, a method is disclosed for searchinghardware description data for an IO hardware device in an industrialautomation system. The method includes: in a development workspace forconfiguring hardware configuration of a plurality of IO modules eachoperatively connected to a slot of an IO hardware device, presenting, bya processor, via a display, a search input comprising a graphicalelement corresponding to an input text field; upon receiving a characterstring in the graphical element corresponding to the input text field,determining one or more matched IO modules, from a collection of IOmodules compatibly associated with the IO hardware device, having ahardware description value matching the input character string byparsing hardware description of each IO modules compatibly associatedwith the IO hardware device, wherein the hardware description value areassociated with a hardware description file (e.g., a general stationdescription (GSD) file or a GSD in XML format (GSDML) file); andpresenting, by the processor, on the development workspace (e.g., on thefirst, second, or third pane), a graphical element corresponding to eachof the determined matched IO modules.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments and together with thedescription, serve to explain the principles of the methods and systems:

FIG. 1 is a screenshot of a development workspace for configuring an IOhardware device having a number of IO modules (or submodules), inaccordance with an embodiment.

FIGS. 2 and 3 are diagrams illustrating an addition of a searched IOmodule to the operational configuration of an IO hardware device (e.g.,via drag and drop operations), in accordance with an embodiment.

FIG. 4 is a screenshot configured to retrieve, via a search JO modulesbased on compatibility with a given slot position, in accordance with anembodiment

FIGS. 5 and 6 are screenshots of a development workspace that displaysgraphical elements associated with a list of compatible JO modules orsubmodules upon selection of a slot position or controller of the JOhardware device, in accordance with an embodiment.

FIG. 7, comprising FIGS. 7A, 7B, 7C, 7D, 7E, 7F, 7G, 7H, 7I, 7J, 7K, 7L,illustrates portions of a GSDML configuration file that are associatedwith the presented discrete input module shown in relation to FIG. 6, inaccordance with an embodiment.

FIG. 8 is a screenshot of the development workplace with a submoduleconfigured from a selection of a retrieved searched submodule, inaccordance with an embodiment.

FIG. 9 is a screenshot of the development workspace presenting a list ofmodules frequently used with a searched module, in accordance with anembodiment.

FIG. 10 is a screenshot of the development workspace of FIG. 1 having apanel to configure input and output settings for a given JO module orsubmodule, in accordance with an embodiment.

FIG. 11 is a screenshot of the development workspace for configuringsettings of a given JO module or submodule, in accordance with anembodiment.

FIG. 12 is a screenshot of an example interface for loading a GSDML filehaving a collection of JO parameters and configuration parametersassociated with a given JO device, in accordance with an embodiment.

FIG. 13 illustrates an exemplary computer, e.g., that executes thedevelopment workspace, that can be used for configuring hardware devicesin an industrial automation system, in accordance with an embodiment.

DETAILED DESCRIPTION

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art. Methods and materials similar or equivalent to those describedherein can be used in the practice or testing of the present disclosure.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Ranges may be expressed herein as from “about” oneparticular value, and/or to “about” another particular value. When sucha range is expressed, another embodiment includes from the oneparticular value and/or to the other particular value. Similarly, whenvalues are expressed as approximations, by use of the antecedent“about,” it will be understood that the particular value forms anotherembodiment. It will be further understood that the endpoints of each ofthe ranges are significant both in relation to the other endpoint, andindependently of the other endpoint.

“Optional” or “optionally” means that the subsequently described eventor circumstance may or may not occur, and that the description includesinstances where said event or circumstance occurs and instances where itdoes not.

Throughout the description and claims of this specification, the word“comprise” and variations of the word, such as “comprising” and“comprises,” means “including but not limited to,” and is not intendedto exclude, for example, other additives, components, integers or steps.“Exemplary” means “an example of” and is not intended to convey anindication of a preferred or ideal embodiment. “Such as” is not used ina restrictive sense, but for explanatory purposes.

Disclosed are components that can be used to perform the disclosedmethods and systems. These and other components are disclosed herein,and it is understood that when combinations, subsets, interactions,groups, etc. of these components are disclosed that while specificreference of each various individual and collective combinations andpermutation of these may not be explicitly disclosed, each isspecifically contemplated and described herein, for all methods andsystems. This applies to all aspects of this application including, butnot limited to, steps in disclosed methods. Thus, if there are a varietyof additional steps that can be performed it is understood that each ofthese additional steps can be performed with any specific embodiment orcombination of embodiments of the disclosed methods.

It is understood that throughout this specification the identifiers“first”, “second”, “third”, “fourth”, “fifth”, “sixth”, and such, areused solely to aid in distinguishing the various components and steps ofthe disclosed subject matter. The identifiers “first”, “second”,“third”, “fourth”, “fifth”, “sixth”, and such, are not intended to implyany particular order, sequence, amount, preference, or importance to thecomponents or steps modified by these terms.

The present methods and systems may be understood more readily byreference to the following detailed description of preferred embodimentsand the Examples included therein and to the Figures and their previousand following description.

FIG. 1 is a screenshot of a development workspace 100 for configuring anIO hardware device (e.g., a Programmable Automation Controller (PAC), aProgrammable Logic Controller (PLC), a Supervisory Control and DataAcquisition (SCADA) System) having a number of IO modules (orsubmodules). The development workspace 100 presents on a first pane 102,one or more graphical elements (shown as 102 a) each corresponding to anIO module or submodule slot associated with the IO hardware device, andon the development workspace, a search input comprising a graphicalelement 104 corresponding to an input text field.

In FIG. 1, main pane 116 shows a “Distributed I/O” 118 having twosubsystems (shown as “PAOC-22” 120 a and “PPNG-L21R” 120 b). As shown,the “PPNG-L21R” subsystem 120 b currently includes a programmableautomation controller (shown as “PAC8000-PNS1 [8515-BI-PN]” 122) withinthe programmable configuration of the IO hardware device in thedevelopment workspace, where PAC8000-PNS1 denotes the IO system type,and 8515-BI-PN denotes a scanner module coupled thereto. As can be seenin FIG. 1, one or more IO hardware system (e.g., PAC, PLC, SCADA) mayform a subsystem with a distributed IO control system. Selection of oneof the IO hardware system, for a given subsystems, in main pane 116causes the development workspace 100 to present module and submoduleslot configurations for the selected IO hardware system.

Referring still to FIG. 1, in response to an input character stringbeing provided in the input text field 104, the development workspace100 presents on a second pane 106 of the development workspace, one ormore graphical elements 108 each corresponding to a given matched IOmodule or submodule. The graphical elements 108 may include a modulename 110 having an associated description that matches, wholly, or inpart, the input character string. In some embodiments, the module name110 may be presented along with descriptions of the module based on thetype of searched performed. For example, in FIG. 1, upon an operatortyping a channel type into the input text field 104, the module name 110is presented along with compatible slot positions 112 to which a modulecorresponding to the module name may be inserted to the IO hardwaredevice. For example, as shown, in response to an input of “8 Analoginput channel”, the development workspace 100 presents four compatiblemodules, including a “8101-HI-TX” analog input module, a “8103-AI-TX”analog input module, a “8119-VI-05” analog input module, and a“8201-HI-IS” analog input module. The “8101-HI-TX” module and“8201-HI-IS” module are connectable, to a module carrier via Railbus, toa high speed Bus Interface Module within the PAC8000-PNS1 system andeach includes 8 channels of 4-20 mA analog inputs with HART (HighwayAddressable Remote Transducer) capabilities. The “8103-AI-TX” moduleincludes 8 channels of 4-20 mA analog inputs. The “8119-VI-05” moduleincludes 8 channels of 1-5V analog inputs.

In an aspect, each of the graphical elements (e.g., 108) associated withthe retrieved module from the performed search and presented in pane 106are selectable to configure the slot configurations of the IO hardwaredevice with the parameters of the selected IO module or submodule. Tothis end, the performed search and subsequent configuring action of theIO hardware device provides a user interface that improves theconfiguration of IO hardware device with IO slots in which the user doesnot have to manually input, into the development workspace, the IOmodule or submodule name or description. In addition, the searching forcompatible IO modules or submodules and those with specific feature setsis fully integrated with the configuring operation of the programmableconfiguration profile for the IO hardware device in the developmentworkspace.

Configuration of IO hardware device with IO slots in developmentworkspace is often a labor-intensive and complex process. A given IOhardware device may be compatible with tens to several hundreds ofdifferent IO module types, which may have submodules for furthercustomization. Although general station description (GSD) in XML format(GSDML) files provide libraries of hardware descriptions for a givenclass of development workspaces, these files are massive havingthousands to tens of thousands of entries. In addition, there is nostandard nomenclature among manufacturers and vendors for commonhardware IO features nor are there standardized nomenclatures todescribe proprietary hardware configurations. In addition, searchingfunctions are limited to string and Boolean searches of the hard-codeddescription in the GSDML file. For these classes of developmentworkspaces, GSDML and hardware XML files are imported and made availableto the user independent of the programming and configuring of theprogramming of the IO hardware. In these classes of developmentworkspaces, a separate search window is often employed.

Referring back to FIG. 1, in some embodiments, the development workspaceis configured to facilitate selection of a retrieved IO module orsubmodule (from the performed search) in pane 106 and configuring ofavailable slots in pane 102 via a drag and drop mechanism. To this end,graphical elements (e.g., 108) in pane 106 may be “dragged and dropped”onto a graphical element in pane 102, which causes the IO module orsubmodule associated with the selected graphical elements to be assignedto configuration profile for a IO hardware device.

FIGS. 2 and 3 are diagrams illustrating an addition of a searched IOmodule to the operational configuration of an IO hardware device (e.g.,via drag and drop operations). In FIG. 2, a first graphical element 202(shown as “8103-AI-TX (Allowed in slots 1 to 32)”) is selected in pane106 and a second graphical element (shown as “slot 4” 204) is selectedin pane 102. In some embodiments, the selection is presented ascheckboxes, buttons, or other graphical widgets. In some embodiments,the selection is made via a “drag and drop” operation. As shown in FIG.2, upon selection of the first graphical element 102 in pane 106 and thedragging of the first graphical element 102 into pane 102, therespective graphical element (corresponding to a slot position of the IOhardware device) in pane 102 to which the description of the selected IOmodule or submodule will be assigned is highlighted. In someembodiments, the development workspace 100 may highlight by a change ofcolor, font, or style of the graphical element.

In some embodiments, upon a selection of a graphical element (e.g., 202)corresponding to a module or submodule from a list of retrieved results108 in pane 106, the development workspace 100 may present highlightcompatible slots of which the selected module or submodule may beapplied. As shown in FIG. 2, the border is presented corresponding tothe slot to which the selected IO module or submodule will be applied.In some embodiments, the development workspace 100 compares the IO slotposition allowance value for a given IO module or submodule to a slotposition value for the IO hardware device.

In response to the addition of a selected IO module (in pane 106) to aprogrammable slot position (in pane 102), the user interface (e.g.,development workspace) is configured to retrieve hardware configurationdata associated with the selected IO module and to update the softwareconfiguration in the development workspace of the IO hardware device.The software configuration is subsequently converted to configurationinstructions to be transmitted to the IO hardware device to configurehardware configuration of the plurality of IO modules connected thereto.As shown in FIG. 2, the first and second panes proximally border eachother.

In some embodiments, the searched parameters of IO modules andsubmodules are available based on a number of analog inputs, a number ofanalog outputs, a number of digital inputs, and a number of digitaloutputs. In some embodiments, the searched parameters are based onMaximum Dimensions (e.g., length), Minimum Operating Temperature,Maximum Operating Temperature, Number of Port connectors, Minimum Updaterate support, Number of analog IO channels per module, Number of digitalIO channels per module, Number of temperature IO channels per module,Maximum IO data rate per device, and Number of Daps supported.

In some embodiments, the input text field is configured to parse aninput search to determine an intermediary parameter to compare to theparameters in a library of IO module and IO submodules. For example, theinput text field, in some embodiments, is configured to receive a stringvalue corresponding to a power compatible search. The developmentworkspace is configured to determine a current maximum or present powerusage by automatically summing individual current maximum power usagefor each IO module presently associated with the IO device (e.g., usedpresented in the first pane 102). The development workspace mayautomatically retrieve a maximum power use for a given IO device todetermine a power budget (as an available power parameter) available foradditional IO modules or submodules. The development workspace mayautomatically compare the required power parameter for each IO moduleand IO submodule compatible to a given IO device and present those thathave a required power parameter within the range of the available powerparameter.

In some embodiments, the development workspace is configured to comparethe inputted string to an index. For example, for the input, “allowedin”, the development workspace is configured to auto-fill the input andpresent a remaining portion of the input as the input is provided intothe search field. For example, upon receiving, “allo . . . ”, thedevelopment workspace may present “Allowed in . . . ” to guide the userto the command. In some embodiments, the development workspace isconfigured to present a list of potential options and to receive aselection of one of the presented options from the user. For example,the development workspace may present “Allowed in Slot 1”, “Allowed inSlot 2”, “Allowed in Slot 3”, “Allowed in Slot 4”, and etc., to whichthe user may select from a presented listed. In some embodiments, thedevelopment workspace is configured to automatically apply wild cardfeatures to an input string search and to disregard capitalization. Insome embodiments, the development workspace may perform a spell checkfunction on the inputted string and perform a comparison of both thespell-checked string and the input string to the repository of IOmodules data and IO submodules data.

FIG. 4 is a screenshot configured to retrieve IO modules based oncompatibility with a given slot position. Specifically, upon receiving acharacter input string (“Allowed in Slot 1”) into input text field 104,the development workspace is configured to compare the inputted stringto a repository of IO modules data and IO submodules data.

The development workspace 100 may maintain an index of searchablehardware description that is created from one or more XML files orGeneric Station Description in XML format (GSDML) files. In someembodiments, the development workspace 100 may create the index fromPROFINET Generic Station Description (GSD) in XML format (GSDML)configuration files. The index may be include a category for each IOhardware device type, a list or range of compatible slot positions onthe IO hardware device, a list of discrete input modules, a list ofdiscrete output modules, a list of discrete mixed modules, a list ofanalog input modules, a list of analog output modules, a list of analogmixed modules, a list of counter modules, a list of compatible powersupply modules, a list of specialty modules, and a list of communicationmodules.

The index may include variations of the textual description for eachlist type. In some embodiments, a secondary search input is alsoaccepted for finer searching. Examples are provided in Table 1. Table 2provides a list of variations of the textual description for eachsubmodule types.

TABLE 1 Primary Search Input Secondary Search Input Compatible SlotPositions allowed in slot <no.> allowed in slots <no.> allow in slot<no.> compatible with slot <no.> compatible in slot <no.> compatiblewith slot <no.> to <no.> compatible with slot <no.>- <no.> can be usedin slot <no.> slot <no.> Discrete input modules discrete input module*<no.> ac isolated input discrete input* <no.>isolated input discrete* acisolated input* input module* ac isolate* input* ac* in* <no.> vacinput* <no.> <no.> vac* <no.> vdc input* <no.> vdc* <no.> dc input*<no.> dc* fast dc* ac/dc* acdc* Discrete output modules discrete outputmodule* <no.> ac output discrete output* ac output* output module* ac*output* <no.> vac out* <no.> vac <no.> isolated output* isolated*isolate* pneumatic outputs* pneumatic* normally open* open* normallyclose* close* <no.> channel* <no.> chan Discrete mixed modules discretemixed module* <no.> vac input* discrete mixed* <no.> vac mixed module*relay output mixed* relay input mix* <no.> channel* <no.> chan<no.>v-<no.>v <no.>v to <no.>v <no.>a-<no.>a <no.>a to <no.>a unipolar*bipolar* Analog input modules analog input module* <no.> bit floatinganalog input* <no.> float input module* <no.> differential* input*differential* in* diff* 4-20ma 420ma <no.> channel* <no.> chan*<no.>v-<no.>v <no.>v to <no.>v <no.>a-<no.>a <no.>a to <no.>a unipolar*bipolar* Analog mixed modules analog mixed module* <no.> bit floatinganalog mixed* <no.> float mixed module* <no.> differential* mixed*differential* mix* diff* 4-20ma 420ma <no.> channel* <no.> chan*<no.>v-<no.>v <no.>v to <no.>v <no.>a-<no.>a <no.>a to <no.>a unipolar*bipolar* Analog output modules analog output module* non-isolated*analog output* not isolated* output module* single-ended output*differential* out* diff* <no.> channel* <no.> chan* Counter Modulescounter module* <no.> counter* counter* interrupt* count* Power SupplyModules power supply module* <no.>watt* power supply* <no.>w* powermodule* greater than <no.>w* power* greater than <no.> supply module* ><no.>w* supply* > <no.> less than <no.>w* less than <no.> < <no.>w* <<no.> Specialty Modules specialty module* specialty* special*Communication Modules Communication module* ethernet* Communication*profinet* Comm* gigabit* fiber*

In some embodiments, the search is performed on the categories in theindex. In some embodiments, the search is performed on the categories inthe index and on the description in the GSDML or XML file. In someembodiments, the search is performed on metadata or tags in the GSDML orXML file.

As stated above, Table 2 provides a list of variations of the textualdescription for each submodule types.

TABLE 2 Discrete input submodules discrete input submodule* discreteinput sub* discrete sub* input submodule* input sub* Discrete outputsubmodules discrete output submodule* discrete output sub* discrete sub*output submodule* output sub* Analog input submodules analog inputsubmodule* analog input sub* analog sub* input submodule* input sub*Analog output submodules analog output submodule* analog output sub*analog sub* output submodule* output sub* Analog mixed submodules analogmixed submodule* analog mixed sub* analog sub* mixed submodule* mixedsub* mix sub*

In another aspect, the development workspace is configured to present,upon selection of a slot position or a controller of the IO hardwaredevice, graphical elements associated with a list of compatible IOmodules or submodules.

FIGS. 5 and 6 are screenshots of a development workspace that displaysgraphical elements associated with a list of compatible IO modules orsubmodules upon selection of a slot position or controller of the IOhardware device. In FIG. 5, upon selection of a slot position (e.g., anyone of 504) or controller 502, the development workspace is configuredto present a list of compatible modules and submodules. The developmentworkspace are displayed, in some embodiments, arranged in accordancewith categories of the compatible modules and submodules. In FIG. 5, thecategories are shown as digital input modules (“DI” 506), digital outputmodules (“DQ” 508), analog input modules (“AI” 510″), analog outputmodules (“AQ” 512), counter modules (“CM” 514), controller modules(“Server modules” 516), and Timer modules (“TM” 518). The categories areassociated with a class of devices referred to as “ET200SP”. Othercategories may be present depending on the available features of modulesand submodules for a given class of device

FIG. 6 illustrate an expanded list of compatible IO module for a givencategory. In FIG. 6, the IO modules are categories are associated with aclass of devices referred to as “RX3i-PNS”.

FIG. 7, comprising FIGS. 7A, 7B, 7C, 7D, 7E, 7F, 7G, 7H, 7I, 7J, 7K, 7L,illustrates portions of a GSDML configuration file that are associatedwith the presented discrete input module shown in relation to FIG. 6.That is, in FIG. 6, the discrete input module 602 is presented based ona GSDML description of the “IC693ACC300” module, the description ofwhich is shown in FIG. 7A. The discrete input module 604 is presentedbased on a GSDML description of the “IC693MDL230” module, thedescription of which is shown in FIG. 7B. Similarly, the discrete inputmodule 606 is presented based on the GSDML description shown in FIG. 7C;the discrete input module 608 is presented based on the GSDMLdescription shown in FIG. 7D; the discrete input module 610 is presentedbased on the GSDML description shown in FIG. 7E; the discrete inputmodule 612 is presented based on the GSDML description shown in FIG. 7F;the discrete input module 614 is presented based on the GSDMLdescription shown in FIG. 7G; the discrete input module 616 is presentedbased on the GSDML description shown in FIG. 7H; the discrete inputmodule 618 is presented based on with GSDML description shown in FIG.7I; the discrete input module 620 is presented based on the GSDMLdescription shown in FIG. 7J; the discrete input module 622 is presentedbased on the GSDML description shown in FIG. 7K; and the discrete inputmodule 624 is presented based on the GSDML description shown in FIG. 7L.

As shown in FIG. 6, each of the module and/or submodule includes amodule name and a textual description corresponding to a feature of themodule. In certain instances, a given module may have two or moreconfigurations (e.g., shown in 602, 612, and 614), which includes acorresponding number of module names and information.

Submodules Configuration

In some embodiments, the submodules of the IO hardware device isconfigurable via the “drag and drop” operation discussed above.

FIG. 8 is a screenshot of the development workplace with a submoduleconfigured from a selection of a retrieved searched submodule. In FIG.8, a module 802 located at “slot 5” is expanded to show an availablesubmodule (shown as 804). Upon selection of the slot 5 sub-slot 1, thedevelopment workspace 100 presents a list of compatible submodules(shown as 806 a and 806 b). In FIG. 8, a compatible submodule isselected and configured to sub-slot 804.

Guided Configuration

In another aspect, the exemplified methods and systems facilitates, viathe user interface, a guided interface to leverage historical retrievedparameters and information, previously build IO device configuration andits respective IO module configuration, and to publish popularIO-device-and-module configurations. In some embodiments, theexemplified methods and systems present configurations ofpreviously-created IO modules and IO devices, which may be loaded to thedevelopment workspace to serve as a baseline or initial configurationfor a given IO-device configuration project. In some embodiments, theexemplified methods and systems facilitates the presentation, thedevelopment workspace, of similar searches of compatible IO modules andsubmodules for a given IO device. In some embodiments, the exemplifiedmethods and systems facilitates the publication of popular IO deviceconfigurations and their respective IO modules and submodules.

The exemplified methods and systems, in some embodiments, maintains arepository of previously built IO device configuration and respective IOmodule and submodule configuration. In some embodiments, the previouslybuilt IO device configuration is maintained in a configuration fileassociated with the development workspace. In some embodiments, theconfiguration file, or contents therein, is periodically updated, via anetwork, with a database to which the development workspace interfaces.

The exemplified methods and systems, in some embodiments, presentconfigurations of previously-created IO modules and IO devices, whichmay be loaded to the development workspace to serve as a baseline orinitial configuration for a given IO-device configuration project. Insome embodiments, the development workspace may present popular orfrequently used counter modules.

In some embodiments, the data associated with the previously-created IOmodules and IO devices, the popular, or frequently used counter modulesare included in the GSDML or XML file. In some embodiments, thedevelopment workspace retrieves the previously-created IO modules and IOdevices, the popular, or frequently used counter modules from a databaseaccessible to the development workspace over a network. In someembodiments, the database is maintained in a network area storage (NAS)or in a cloud environment.

Referring back to FIG. 5, the development workspace is shown presentinga list of frequently used modules. In FIG. 5, the frequently used modulefor the IO hardware device (e.g., 502 or 520) is a counter module (shownas “CM” 522). In some embodiments, the category and subcategoryassociated with the modules (shown as 524 a and 524 b) are alsopresented.

FIG. 9 is a screenshot of the development workspace presenting a list ofmodules frequently used with a searched module. In FIG. 9, modulesfrequently used with counter modules are shown. Specifically, inresponse to a search for counter modules, the development workspacepresents a second counter module (shown as “Point-to-Point CM PtP” 802)and a third counter module (shown as “IO link master CM 4xIO-Link V1”804).

Other types of information may be maintained by the developmentworkspace. In some embodiments, the exemplified methods and systemsfacilitates the presentation, the development workspace, of similarsearches of compatible IO modules and submodules for a given IO device.

In some embodiments, the repository facilitates, in some embodiments,via the user interface, a guided interface to leverage historicalretrieved parameters and information.

In some embodiments, the development workspace maintains a list ofpopular IO-device-and-module configurations. In some embodiments, a3^(rd) party computing device (e.g., a cloud system) operativelyreceives IO-device-and-module configurations from each developmentworkspace to determine the list of popular IO-device-and-moduleconfigurations.

FIG. 10 is a screenshot of the development workspace of FIG. 1 having apanel to configure input and output settings for a given IO module orsubmodule. As shown in FIG. 10, analog output channels of the IO moduleare configurable as 0 to 10V, −10 to +10V, 4-20 mA, and 0-20 mA. Theseconfigurable parameters may be searched via the input text string 104(shown in FIGS. 1-5).

FIG. 11 is a screenshot of the development workspace of FIG. 1 having apanel to configure settings of a given IO module or submodule. As shownin FIG. 11, example settings include range type, software filtering,diagnostic reporting, fault reporting, low alarm, high alarm, underrange notification, over range notification, open wire notification,low-low alarm, high-high alarm, negative range detection notification,and positive range detection notification. These configurable parametersare exemplary parameters to which the input text string 104 may alsoreceive IO modules having such attributes or types.

FIG. 12 is a screenshot of an example interface for loading a GSDML filehaving a collection of IO parameters and configuration parametersassociated with a given IO device. The GSDML files are, in someembodiments, stored in XML format.

FIG. 13 illustrates an exemplary computer, e.g., that executes thedevelopment workspace, that can be used for configuring hardware devicesin an industrial automation system. In various aspects, the computer ofFIG. 13 may comprise all or a portion of the development workspace 100,as described herein. As used herein, “computer” may include a pluralityof computers. The computers may include one or more hardware componentssuch as, for example, a processor 1321, a random access memory (RAM)module 1322, a read-only memory (ROM) module 1323, a storage 1324, adatabase 1325, one or more input/output (I/O) devices 1326, and aninterface 1327. Alternatively and/or additionally, controller 1320 mayinclude one or more software components such as, for example, acomputer-readable medium including computer executable instructions forperforming a method associated with the exemplary embodiments. It iscontemplated that one or more of the hardware components listed abovemay be implemented using software. For example, storage 1324 may includea software partition associated with one or more other hardwarecomponents. It is understood that the components listed above areexemplary only and not intended to be limiting.

Processor 1321 may include one or more processors, each configured toexecute instructions and process data to perform one or more functionsassociated with a computer for indexing images. Processor 1321 may becommunicatively coupled to RAM 1322, ROM 1323, storage 1324, database1325, I/O devices 1326, and interface 1327. Processor 1321 may beconfigured to execute sequences of computer program instructions toperform various processes. The computer program instructions may beloaded into RAM 1322 for execution by processor 1321. As used herein,processor refers to a physical hardware device that executes encodedinstructions for performing functions on inputs and creating outputs.

RAM 1322 and ROM 1323 may each include one or more devices for storinginformation associated with operation of processor 1321. For example,ROM 1323 may include a memory device configured to access and storeinformation associated with controller 1320, including information foridentifying, initializing, and monitoring the operation of one or morecomponents and subsystems. RAM 1322 may include a memory device forstoring data associated with one or more operations of processor 1321.For example, ROM 1323 may load instructions into RAM 1322 for executionby processor 1321.

Storage 1324 may include any type of mass storage device configured tostore information that processor 1321 may need to perform processesconsistent with the disclosed embodiments. For example, storage 1324 mayinclude one or more magnetic and/or optical disk devices, such as harddrives, CD-ROMs, DVD-ROMs, or any other type of mass media device.

Database 1325 may include one or more software and/or hardwarecomponents that cooperate to store, organize, sort, filter, and/orarrange data used by controller 1320 and/or processor 1321. For example,database 1325 may store hardware and/or software configuration dataassociated with input-output hardware devices and controllers, asdescribed herein. It is contemplated that database 1325 may storeadditional and/or different information than that listed above.

I/O devices 1326 may include one or more components configured tocommunicate information with a user associated with controller 1320. Forexample, I/O devices may include a console with an integrated keyboardand mouse to allow a user to maintain a database of images, updateassociations, and access digital content. I/O devices 1326 may alsoinclude a display including a graphical user interface (GUI) foroutputting information on a monitor. I/O devices 1326 may also includeperipheral devices such as, for example, a printer for printinginformation associated with controller 1320, a user-accessible diskdrive (e.g., a USB port, a floppy, CD-ROM, or DVD-ROM drive, etc.) toallow a user to input data stored on a portable media device, amicrophone, a speaker system, or any other suitable type of interfacedevice.

Interface 1327 may include one or more components configured to transmitand receive data via a communication network, such as the Internet, alocal area network, a workstation peer-to-peer network, a direct linknetwork, a wireless network, or any other suitable communicationplatform. For example, interface 1327 may include one or moremodulators, demodulators, multiplexers, demultiplexers, networkcommunication devices, wireless devices, antennas, modems, and any othertype of device configured to enable data communication via acommunication network.

While the methods and systems have been described in connection withpreferred embodiments and specific examples, it is not intended that thescope be limited to the particular embodiments set forth, as theembodiments herein are intended in all respects to be illustrativerather than restrictive.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is no way intended thatan order be inferred, in any respect. This holds for any possiblenon-express basis for interpretation, including: matters of logic withrespect to arrangement of steps or operational flow; plain meaningderived from grammatical organization or punctuation; the number or typeof embodiments described in the specification.

Throughout this application, various publications are referenced. Thedisclosures of these publications in their entireties are herebyincorporated by reference into this application in order to more fullydescribe the state of the art to which the methods and systems pertain.It will be apparent to those skilled in the art that variousmodifications and variations.

What is claimed is:
 1. A method of configuring a hardware device in anindustrial automation system, the method comprising: in a developmentworkspace for configuring hardware configuration of a plurality ofinput-output (IO) modules each operatively connected to a slot of an IOhardware device, presenting, by a processor, via a display, i) on afirst pane of the development workspace, one or more graphical elementseach corresponding to an IO module slot associated with the IO hardwaredevice, and ii) on the development workspace, a search input comprisinga graphical element corresponding to an input text field; upon receivingan input character string in the input text field, determining, by theprocessor, one or more matched IO modules, from a collection of IOmodules compatibly associated with the IO hardware device, having ahardware description value matching the input character string, whereinthe hardware description value are associated with a hardwaredescription file; presenting, by the processor, via the display, on asecond pane of the development workspace, one or more graphical elementseach corresponding to a given matched IO module; and upon receiving aselection, in the second pane, of a presented graphical elementcorresponding to a matched IO module and, in the first pane, a presentedIO module slot, updating presentation of the graphical elementassociated with the selected IO module slot with a graphical elementassociated with the selected IO module.
 2. The method of claim 1,comprising: retrieving, by the processor, hardware configuration dataassociated with the selected IO module; and updating, by the processor,software configuration of the development workspace, wherein thesoftware configuration is subsequently converted to configurationinstructions to be transmitted to the IO hardware device to configurehardware configuration of the plurality of IO modules connected thereto.3. The method of claim 1, wherein the first and second panes proximallyborder each other.
 4. The method of claim 1, wherein the graphicalelement comprising the input text field is presented in a pane selectedfrom the group consisting of the first pane, the second pane, and athird pane of the development workspace.
 5. The method of claim 1,wherein the step of determining the one or more matched IO modulescomprises comparing the received character string to hardwaredescription of each IO modules compatibly associated with the IOhardware device.
 6. The method of claim 5, wherein the hardwaredescription of a given IO module comprises IO description data isselected from the group consisting of: a number of analog inputs, anumber of analog outputs, a number of digital inputs, and a number ofdigital outputs.
 7. The method of claim 1, wherein the input characterstring comprises a string value corresponding to a slot-compatiblesearch, the method comprising: parsing, by the processor, hardwaredescription of each IO modules compatibly associated with the IOhardware device; and for each IO module having a hardware descriptiondetermined to have an operable slot range value that includes the stringvalue corresponding to the slot-compatible search, presenting, by theprocessor, on the second pane of the development workspace, a graphicalelement corresponding to the given IO module.
 8. The method of claim 7,wherein the step of parsing hardware description of each IO modulescompatibly associated with the IO hardware device comprises: parsingeach hardware description data associated with each given IO module. 9.The method of claim 7, wherein the step of parsing hardware descriptionof all IO modules compatibly associated with the IO hardware devicecomprises: determining a description type for the input character stringfrom a list of potential description type; parsing hardware descriptiondata associated with a determined description type for each given IOmodule.
 10. The method of claim 1, wherein the input character stringcomprises a string value corresponding to a power-limit-compatiblesearch, the method comprises: determining, by the processor, anavailable power value for the IO hardware device by subtracting amaximum available power value for the IO hardware device with a currentpower usage value for a current configuration of the IO hardware device;parsing, by the processor, hardware description of power requirementvalue of each IO modules compatibly associated with the IO hardwaredevice; and for each given IO module having, in the hardwaredescription, a power requirement value less than the determinedavailable power value, presenting, by the processor, on the developmentworkspace, a graphical element corresponding to the given IO module. 11.The method of claim 10, comprising: presenting, by the processor, viathe display, in the development workspace, graphical representation ofthe available power value for the IO hardware device.
 12. The method ofclaim 1, wherein the input character string comprises a string valuecorresponding to a temperature compatible search, the method comprising:parsing, by the processor, hardware description of each IO modulescompatibly associated with the IO hardware device; for each IO modulehaving a hardware description determined to have an operable temperatureoperating range value that includes the string value corresponding tothe temperature compatible search, presenting, by the processor, on thesecond pane of the development workspace, a graphical elementcorresponding to the given IO module.
 13. The method of claim 1, whereinthe input character string comprises a string corresponding to adimensions-compatible search, the method comprising: parsing, by theprocessor, hardware description of each IO modules compatibly associatedwith the IO hardware device; for each IO module having a hardwaredescription determined to have a maximum dimension value less than thestring value corresponding to the dimensions-compatible search,presenting, by the processor, on the second pane of the developmentworkspace, a graphical element corresponding to the given IO module. 14.The method of claim 1, wherein the input character string comprises astring corresponding to a search parameter selected from the groupconsisting of Maximum Dimensions, Minimum Operating Temperature, MaximumOperating Temperature, Number of Port connectors, Minimum Update ratesupport, Number of analog IO channels per module, Number of digital IOchannels per module, Number of temperature IO channels per module,Maximum IO data rate per device, and Number of Daps supported; themethod comprises: determining, by the processor, a hardware descriptiontype associated with the search string type; parsing, by the processor,hardware description of each IO modules compatibly associated with theIO hardware device; and for each IO module having a hardware descriptiondetermined to have a value that meets the criteria of the searchparameter, presenting, by the processor, on the second pane of thedevelopment workspace, a graphical element corresponding to the given IOmodule.
 15. The method of claim 1, comprising: presenting, by theprocessor, via the display, graphical representation of IO moduleconfigurations for a past-built IO hardware device, wherein thepast-built IO hardware device has a first slot configuration and the IOhardware device has a second slot configuration, wherein the first slotconfiguration is the same with the second slot configuration.
 16. Themethod of claim 1, comprising: presenting, by the processor, via thedisplay, graphical representation of one or more historical searchstring submitted for the given IO hardware device, wherein thehistorical search string includes a portion of the input characterstring.
 17. The method of claim 1, comprising: presenting, by theprocessor, via the display, graphical representation of most used IOmodules for the IO hardware device.
 18. The method of claim 1,comprising: presenting, by the processor, via the display, i) on a firstpane of the development workspace, one or more second graphical elementseach corresponding to an IO sub-module slot associated with the IOhardware device; upon receiving the input character string in the inputtext field, determining, by the processor, one or more matched IOsubmodules, from a collection of IO submodules compatibly associatedwith the IO hardware device, having a hardware description valuematching the input character string; presenting, by the processor, viathe display, on the second pane of the development workspace, one ormore second graphical elements each corresponding to a given matched IOsub-module; and upon receiving a selection, in the second pane, of apresented second graphical element corresponding to a matched IOsubmodule and, in the first pane, a presented IO submodule slot,updating presentation of the second graphical element associated withthe selected IO submodule slot with a graphical element associated withthe selected IO submodule.
 19. A system of configuring an IO hardwaredevice in an industrial automation system via a development workspacefor configuring hardware configuration of a plurality of IO modules eachoperatively connected to a slot of the IO hardware device, the systemcomprising: a processor; a memory having instructions stored thereon,wherein the instructions, when executed by the processor, cause theprocessor to: present, via a display, i) on a first pane of thedevelopment workspace, one or more graphical elements each correspondingto an IO module slot associated with the IO hardware device, and ii) onthe development workspace, a search input comprising a graphical elementcorresponding to an input text field; upon receiving a character stringin the graphical element, determine one or more matched IO modules, froma collection of IO modules compatibly associated with the IO hardwaredevice, having a hardware description value matching the input characterstring, wherein the hardware description value are associated with ahardware description file; present, via the display, on a second pane ofthe development workspace, one or more graphical elements eachcorresponding to a given matched IO module; and upon receiving aselection, in the second pane, of a presented graphical elementcorresponding to a matched IO module and, in the first pane, a presentedIO module slot, update presentation of the graphical element associatedwith the selected IO module slot with a graphical element associatedwith the selected IO module.
 20. A method of searching hardwaredescription data for an IO hardware device in an industrial automationsystem, the method comprising: in a development workspace forconfiguring hardware configuration of a plurality of IO modules eachoperatively connected to a slot of an IO hardware device, presenting, bya processor, via a display, a search input comprising a graphicalelement corresponding to an input text field; upon receiving a characterstring in the graphical element corresponding to the input text field,determining one or more matched IO modules, from a collection of IOmodules compatibly associated with the IO hardware device, having ahardware description value matching the input character string byparsing hardware description of each IO modules compatibly associatedwith the IO hardware device, wherein the hardware description value areassociated with a hardware description file; and presenting, by theprocessor, on the development workspace, a graphical elementcorresponding to each of the determined matched IO modules.